Electrical connection and method of making same

ABSTRACT

An electrical connection with an electrical contact member and comprising a cylindrical helix of electrically conductive resilient wire having a first end electrically connecting with the contact member and a second end adjacent the opening into the free end of the cylindrical helix, and a terminal member including a tapered longitudinal shank portion inserted through the helix opening and into the helix, and having an intermediate region contacting and frictionally engaging the inner perihery of the spiral at the free end of the helix when the shank portion of the terminal member is inserted into the helix. The terminal member can then be rotated to partially unwind the spirals of the helix while further inserting the shank portion of the terminal member into the helix for further frictional engagement between the shank portion and the inner peripheries of additional spirals of the helix. The method of making an electric connection with an electrical contact member is also covered.

United States Patent [191 Brouneus ELECTRICAL CONNECTION AND METHOD OFMAKING SAME [75] Inventor: Harold A. Brouneus, Painted Post,

[73] Assignee: Corning Glass Works, Corning,

[22] Filed: June 3, 1974 [21] Appl. No.: 475,664

Primary Examiner-Roy Lake Assistant ExaminerE. F. Desmond Attorney,Agent, or FirmCharles W. Gregg; Clarence R. Patty, Jr.

{57] ABSTRACT An electrical connection with an electrical contact memberand comprising a cylindrical helix of electri cally conductive resilientwire having a first end electrically connecting with the contact memberand a second end adjacent the opening into the free end of thecylindrical helix, and a terminal member including a taperedlongitudinal shank portion inserted through the helix opening and intothe helix, and having an intermediate region contacting and frictionallyengaging the inner perihery of the spiral at the free end of the helixwhen the shank portion of the terminal member is inserted into thehelix. The terminal member can then be rotated to partially unwind thespirals of the helix while further inserting the shank portion of theterminal member into the helix for further frictional engagement betweenthe shank portion and the inner peripheries of additional spirals of thehelix. The method of making an electric connection with an electricalcontact member is also covered.

10 Claims, 2 Drawing Figures ELECTRICAL CONNECTION AND METHOD OF MAKINGSAME BACKGROUND OF THE INVENTION There is disclosed, for example, incopending application, Ser. No. 475,]96, filed May 31, 1974 by EverettF. Kelm and assigned to the same assignee as the present application, anelectrical contact member comprising a volute helix or conical spiral ofa length of a resilient electrically conductive wire for making electriccontact with an electrically conductive flat surface against which thelargest spiral of the helix is first disposed and the helix thencompressed to move the other spirals of the helix into physical andelectrical contact with the flat surface. In order to readily make anelectrical connection to a contact member such as disclosed in saidcopending application the electrical connection of the presentapplication was developed, such electrical connection being readilyremoved or disconnected if or when it is desired to do so.

SUMMARY OF THE INVENTION An adequate summary of the invention isbelieved to be set forth in the foregoing abstract of the disclosureand, therefore, in order to prevent repetition or redundancy and for thesake of brevity of the application to the extent possible, no furthersummary of the invention is believed necessary nor will any be given.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a side elevational view ofan electrical contact member and an electrical connection with suchcontact member, such connection embodying the invention disclosed; and

FIG. 2 is a side elevational view of the contact member and connectionof FIG. I when such member is used in making contact with a flatelectrically conductive surface.

Similar reference characters refer to similar parts in each of the FIGS.of the drawings.

PREFERRED EMBODIMENT OF THE INVENTION Referring to the two drawingfigures in detail, there is shown in FIG. I an electrical contact membercomprising a volute helix or conically spiraled length 12 ofelectrically conductive resilient wire 1 1 including a plurality ofturns or spirals which progressively increase in size, that is, indiameter or circumference such that each succeeding spiral or turn willsurround the immediately preceding spiral or turn, or the precedingspirals or turns when the volute helix or conically spiraled length 12of wire 11 is compressed or flattened as illustrated in FIG. 2. Thecorrespondence between the volute helix or conically spiraled length 12of wire 11 of the present disclosure and the helix or spiraled length 12of wire 11 of the electric contact member of the aforesaid eopendingapplication, Ser. No. 475,196 of E. F. Kelm will be readily apparentfrom a brief comparison of the drawings of the applications.

In order to make a rapid and secure but readily disconnectableelectrical connection with a contact member comprising a volute helixsuch as I2 of wire 11 such as discussed above and shown in the drawings,a cylindrical helix 18 of electrically conductive resilient wire such as11a has a first end electrically connecting with the end of the smallestone of the spirals of volute helix 12 of wire 11 and a second end at oradjacent the opening 18a into the free end of the cylindrical helix 18.It is preferable that wire 11a actually be, as shown in the drawings, afurther length or a part of the length or wire 11 used to form volutehelix 12 so that the wire forming cylindrical helix 18 is integrallyelectrically connected with such wire 11 forming helix 12. However, thelength of wire Ila, if for some reason it is found to be desirable orexpedient, can be a separate length of electrically conductive resilientwire which, as mentioned above, has a first end electrically connectedto the end of the smallest one of the spirals of volute helix 12, suchconnection being made in any convenient manner such as, for example, bytwisting and soldering of ends of wires 11 and 11a to each other.

An electrically conductive terminal member I9 is provided and includes afirst portion 190 having a pair of opposite lugs such as 19c forelectrically connecting an electrical conductor such as a wire 20 toterminal member 19 by inserting a short section of the length of wire 20between said lugs and crimping the lugs about such wire section and, insome embodiments, also soldering the wire section and the lugs to eachother by solder designated 21. Terminal member 19 further includes alongitudinal shank portion 1% which extends from first portion 190 ofthe terminal member and has a generally circular outer periphery whichtapers from first portion 190 towards the end of the shank portion 19bof the terminal member with an intermediate region of such shank portionhaving a diameter corresponding in diameter to said opening 18a in theaforesaid free end of cylindrical helix 18. The end of shank portion 19bof terminal member 19 is inserted through opening in the free end ofhelix l8 and into the interior of such helix until said intermediateregion of shank portion 19b contacts and frictionally engages with theinner periphery of the spiral at the free end of helix l8. Terminalmember 19 is then manually rotated to partially and temporarily ormomentarily unwind some of the spirals of cylindrical helix 18 while theshank portion 19b of terminal member 19 is simultaneously furtherinserted into the cylindrical helix for frictional engagement betweenpart of the outer periphery of said shank portion of the terminal memberand the inner peripheries of additional spirals of the cylindricalhelix. Terminal member 19 is then released and the partially unwoundspirals of cylindrical helix l8 tend to return toward their woundconditions to tighten even further about the contacted outer peripheryof shank portion 19b of terminal member 19 and provide tight physicaland electrical contact between the contacted and engaged part of saidshank portion and the inner peripheries of said additional spirals aswell as said end spiral of helix 18.

In making electrical connections such as disclosed herein, the largestspiral of the volute helix or conically spiral length 12 of electricallyconductive resilient wire 11 is disposed in contact with a flatelectrically conductive surface such as, for example, a thinelectrically conductive film l4 deposited on a suitable flat substratesuch as 15 as illustrated in FIG. 2, and such volute helix or spiraledlength of wire is then compressed or flattened so that all of thespirals of the spiraled length or helix 12 of wire 11 are pressed intophysical and electrical contact with said conductive film at, at least,two points on each said spiral. Terminal member 19 is then inserted intothe interior of the cylindrical helix l8 and rotated as previouslydiscussed to make electrical connection to helix l8 and, thereby, tohelix l2 and conductive film 14 on substrate 15. Alternatively, theelectrical connection between helix l8 and terminal member 19 can bemade before helix 12 is disposed against and compressed into contactwith film 14 on substrate 15. The electrical connection between wire 20and terminal member 19 can be made at any time. that is. prior to thetime the electrical connection is made between helix 18 and terminalmember 19, or subsequent to such time.

No claim is made herein to the volute helix or conically spiral length12 of wire 11 per se, that is, to the electrical contact member per secomprising the volute helix of wire 12 and forming the electricalcontact member shown in the drawings, since such member is the inventionof the aforesaid E. F. Kelm as previously pointed out. Furthermore,although the electrical connection or electrical connection assembly ofthe invention covered by the present application is shown and describedas an addition to a contact member such as covered by the aforesaidpending patent application of E. F, Kelm. it is pointed out that anelectrical connection or assembly such as herein disclosed can be usedwith other suitable types of electrical contact members for makingelectrical contact with an electrical device or devices.

Although there is herein shown and described only a single form of anelectrical connection embodying the invention, it will be understoodthat such is not intend ing to be in any way limiting but that variouschanges may be made therein within the purview of the ap pended claimswithout departing from the spirit and scope of the invention.

What is claimed is:

1. In an electrical contact member for making an electrical connectionwith an electrically conductive flat surface and including a volutehelix of electrically conductive resilient wire including a successionof spi rals progressively increasing in size such that each suc ceedingspiral will surround the preceding spirals when the helix is compressedagainst said flat surface, the combination therewith of an electricalconnection with said contact member, such connection comprising; acylindrical helix of electrically conductive resilient wire having afirst end electrically connecting with the end of the smallest one ofsaid spirals of said volute helix and a second end at the opening intothe free end of such cylindrical helix; an electrically conductiveterminal member including a first portion for connecting an electricalconductor to such terminal member and a longitudinal shank portionextending from said first portion of the terminal member. and having agenerally circular outer periphery which tapers from said first portiontowards the end of said shank portion of the terminal member with anintermediate region of such shank portion having a diametercorresponding in diameter to said opening in said free end of saidcylindrical helix such shank portion of the terminal member beinginserted through such opening and into the cylindrical helix with saidintermediate region of the shank portion frictionally engaging the innerperiphery of the end spiral of the cylindrical helix at said free endthereof, whereby said terminal member can then be manually rotated topartially and temporarily unwind some of the spirals of the cylindricalhelix while simultaneously further inserting the shank portion of theterminal member into the cylindrical helix for frictional engagementbetween the shank portion of the terminal member and the innerperipheries of additional spirals of the cylindrical helix.

2. The combination in accordance with claim 1 and further including apair of oppositely disposed lugs on said first portion of said terminalmember and an electrical conductor electrically connected with saidlugs.

3. The combination in accordance with claim 2 and in which saidelectrical conductor is soldered to said lugs.

4. An electrical contact member and an electrical connection therewithcomprising; a length of electrically conductive resilient wire, a firstpart of which is formed into a volute helix including a succession ofspirals progressively increasing in size such that each succeedingspiral of such helix will surround the preceding spirals of the helixwhen the largest of the spirals of the helix is placed in contact with aflat surface and said helix is then compressed to move the remainder ofthe spirals of the helix into contact with such surface, and a secondpart of which wire is formed into a cylindrical helix having a first endintegrally connecting with the end ofthe smallest spiral of said volutehelix and a second end at the opening into the free end of suchcylindircal helix, an electrically conductive terminal member includinga first portion for connecting an electrical conductor to such terminalmember and a longitudinal shank portion extending from said firstportion of the terminal member and having a generally circular outerperiphery which tapers from said first portion towards the end of theshank portion of the terminal member with an intermediate region of suchshank portion having a diameter corresponding to said opening in saidfree end of said cylindrical helix, such shank portion of the terminalmember being inserted through said open ing and into the interior of thecylindrical helix with said intermediate region of the shank portionfrictionally engaging the inner periphery of the end spiral of thecylindrical helix and then rotated and further inserting into thecylindrical helix for frictional engagement between the shank portion ofthe terminal member and the inner peripheries of additional spirals ofthe cylindrical helix.

5. An electrical contact member and electrical connection as in claim 4and further including an electrically conductive lug on said firstportion of said termi nal member and an electrical conductorelectrically connected to said lug.

6. An electrical contact member and electrical con nection in accordancewith claim 5 and in which said electrical conductor is soldered to saidlug.

7. The method of making an electrical connection with an electricalcontact comprising a length of electrically conductive resilient wirepart of which is formed into a volute helix for pressing against an electrically conductive flat surface for making electrical contact therewithand the remaining part of such wire extending from the smallest spiralof such helix, said method comprising; forming said remaining part ofsaid wire into a cylindrical helix; providing a longitudinalelectrically conductive terminal member including a first portion havinga lug for securing an electrical conductor to such terminal member and alongitudinal shank portion extending from said first portion of theterminal member and having a generally circular outer periphery whichtapers from said first portion towards the end of said shank portion ofthe terminal member with an intermediate region of such shank portionhaving a diameter corresponding to the diameter of the opening in thefree end of said cylindrical helix; inserting said shank portion of saidterminal member through said opening and firmly into said cylindricalhelix to provide physical contact and frictional engagement between saidintermediate region of said shank portion and the inner periphery of thespiral of wire at said free end of such cylindrical helix; rotating saidterminal member to partially unwind said cylindrical helix while furtherfirmly inserting the shank portion of said terminal member into suchhelix to provide physical contact and frictional engagement between saidintermediate region of such shank portion and the inner peripheries ofadditional spirals of the cylindrical helix; and then releasing saidterminal member to permit the cylindrical helix to return towards itspreviously wound condition and said spirals of such helix to therebysecurely tighten about said intermediate region of said shank portion ofsaid terminal member.

8. The method in accordance with claim 7 and including the further stepof electrically connecting an electrical conductor to said lug on saidfirst portion of said terminal member.

9. The method in accordance with claim 8 and in which said electricalconductor is soldered to said lug.

10. In combination with a contact member for making electrical contactwith an electrical device, an electrical connection assembly comprising;a cylindrical helix of an electrically conductive resilient wire, suchhelix having a selected internal diameter and a first of its endsadapted for connecting with said contact member; and an elongategenerally circular terminal member having a first portion adjacent thefirst end thereof and adapted for connecting with an electricalconductor, and a second portion extending between said first portion andthe second end of the terminal member, such second portion tapering froma first diameter larger than said selected internal diameter of saidhelix to a second diameter smaller than such internal diameter, thesmaller diameter end and part of the length of such second portion ofsaid terminal member being inserted into the second end of said helixand into firm engagement with the spiral at such second end of the helixand then manually rotated to partially unwind said helix while insertingthe second portion of the terminal member further into the helix;whereby said terminal member can then be released to permit the helix torewind and tightly engage an intermediate region of the outer peripheryof the second portion of the terminal member.

=l= k =l=

1. In an electrical contact member for making an electrical connectionwith an electrically conductive flat surface and including a volutehelix of electrically conductive resilient wire including a successionof spirals progressively increasing in size such that each succeedingspiral will surround the preceding spirals when the helix is compressedagainst said flat surface, the combination therewith of an electricalconnection with said contact member, such connection comprising; acylindrical helix of electrically conductive resilient wire having afirst end electrically connecting with the end of the smallest one ofsaid spirals of said volute helix and a second end at the opening intothe free end of such cylindrical helix; an electrically conductiveterminal member including a first portion for connecting an electricalconductor to such terminal member and a longitudinal shank portionextending from said first portion of the terminal member, and having agenerally circular outer periphery which tapers from said first portiontowards the end of said shank portion of the terminal member with anintermediate region of such shank portion having a diametercorresponding in diameter to said opening in said free end of saidcylindrical helix such shank portion of the terminal member beinginserted through such opening and into the cylindrical helix with saidintermediate region of the shank portion frictionally engaging the innerperiphery of the end spiral of the cylindrical helix at said free endthereof, whereby said terminal member can then be manually rotated topartially and temporarily unwind some of the spirals of the cylindricalhelix while simultaneously further inserting the shank portion of theterminal member into the cylindrical helix for frictional engagementbetween the shank portion of the terminal member and tHe innerperipheries of additional spirals of the cylindrical helix.
 2. Thecombination in accordance with claim 1 and further including a pair ofoppositely disposed lugs on said first portion of said terminal memberand an electrical conductor electrically connected with said lugs. 3.The combination in accordance with claim 2 and in which said electricalconductor is soldered to said lugs.
 4. An electrical contact member andan electrical connection therewith comprising; a length of electricallyconductive resilient wire, a first part of which is formed into a volutehelix including a succession of spirals progressively increasing in sizesuch that each succeeding spiral of such helix will surround thepreceding spirals of the helix when the largest of the spirals of thehelix is placed in contact with a flat surface and said helix is thencompressed to move the remainder of the spirals of the helix intocontact with such surface, and a second part of which wire is formedinto a cylindrical helix having a first end integrally connecting withthe end of the smallest spiral of said volute helix and a second end atthe opening into the free end of such cylindircal helix, an electricallyconductive terminal member including a first portion for connecting anelectrical conductor to such terminal member and a longitudinal shankportion extending from said first portion of the terminal member andhaving a generally circular outer periphery which tapers from said firstportion towards the end of the shank portion of the terminal member withan intermediate region of such shank portion having a diametercorresponding to said opening in said free end of said cylindricalhelix, such shank portion of the terminal member being inserted throughsaid opening and into the interior of the cylindrical helix with saidintermediate region of the shank portion frictionally engaging the innerperiphery of the end spiral of the cylindrical helix and then rotatedand further inserting into the cylindrical helix for frictionalengagement between the shank portion of the terminal member and theinner peripheries of additional spirals of the cylindrical helix.
 5. Anelectrical contact member and electrical connection as in claim 4 andfurther including an electrically conductive lug on said first portionof said terminal member and an electrical conductor electricallyconnected to said lug.
 6. An electrical contact member and electricalconnection in accordance with claim 5 and in which said electricalconductor is soldered to said lug.
 7. The method of making an electricalconnection with an electrical contact comprising a length ofelectrically conductive resilient wire part of which is formed into avolute helix for pressing against an electrically conductive flatsurface for making electrical contact therewith and the remaining partof such wire extending from the smallest spiral of such helix, saidmethod comprising; forming said remaining part of said wire into acylindrical helix; providing a longitudinal electrically conductiveterminal member including a first portion having a lug for securing anelectrical conductor to such terminal member and a longitudinal shankportion extending from said first portion of the terminal member andhaving a generally circular outer periphery which tapers from said firstportion towards the end of said shank portion of the terminal memberwith an intermediate region of such shank portion having a diametercorresponding to the diameter of the opening in the free end of saidcylindrical helix; inserting said shank portion of said terminal memberthrough said opening and firmly into said cylindrical helix to providephysical contact and frictional engagement between said intermediateregion of said shank portion and the inner periphery of the spiral ofwire at said free end of such cylindrical helix; rotating said terminalmember to partially unwind said cylindrical helix while further firmlyinserting the shank portion of said terminal member into such helix toprovide physical contact and frictional engagement between saidintermediate region of such shank portion and the inner peripheries ofadditional spirals of the cylindrical helix; and then releasing saidterminal member to permit the cylindrical helix to return towards itspreviously wound condition and said spirals of such helix to therebysecurely tighten about said intermediate region of said shank portion ofsaid terminal member.
 8. The method in accordance with claim 7 andincluding the further step of electrically connecting an electricalconductor to said lug on said first portion of said terminal member. 9.The method in accordance with claim 8 and in which said electricalconductor is soldered to said lug.
 10. In combination with a contactmember for making electrical contact with an electrical device, anelectrical connection assembly comprising; a cylindrical helix of anelectrically conductive resilient wire, such helix having a selectedinternal diameter and a first of its ends adapted for connecting withsaid contact member; and an elongate generally circular terminal memberhaving a first portion adjacent the first end thereof and adapted forconnecting with an electrical conductor, and a second portion extendingbetween said first portion and the second end of the terminal member,such second portion tapering from a first diameter larger than saidselected internal diameter of said helix to a second diameter smallerthan such internal diameter, the smaller diameter end and part of thelength of such second portion of said terminal member being insertedinto the second end of said helix and into firm engagement with thespiral at such second end of the helix and then manually rotated topartially unwind said helix while inserting the second portion of theterminal member further into the helix; whereby said terminal member canthen be released to permit the helix to rewind and tightly engage anintermediate region of the outer periphery of the second portion of theterminal member.